Method of forging of various shaped elements on elongated bars and a device for the use of this method

ABSTRACT

Forging of shaped elements on or from bars is performed by the upsetting of a section of the bar along its axis with a simultaneous squeezing of a part of this section which takes place in a direction transverse to the axis of the bar. Shaping of the product takes place in a device which cooperates with a press or is driven in another way. The device consists of two sets. A set consists of a plate with bearing rollers, a housing for dies with bearing rollers for connectors located between these rollers and linking elements which suspend the housing of the dies to the plates. To the plates, shaping punches are fixed. During forging operation, the bar is fastened between split dies.

United States Patent [1 1 Rut [ Feb. 25, 1975 METHOD OF FORGING OF VARIOUS SHAPED ELEMENTS ON ELONGATED BARS AND A DEVICE FOR THE USE OF THIS METHOD [76] Inventor: Tadeusz Rut, Poznan, Nowe Zagorze, str. 14, Poland [22] Filed: July 31, 1972 [21] Appl. No.: 276,722

[30] Foreign Application Priority Data July 31, 1971 Poland 149788 [52] US. Cl 72/399, 29/6, 72/404 [51] Int. Cl B2lj 5/08 [58] Field of Search 72/399, 354, 383, 377, 72/309, 404, 353, 357, 402; 29/6; 10/26, 78

[56] References Cited UNITED STATES PATENTS 426,652 4/1890 Aiken 72/354 1,946,117 2/1934 Sparks 72/354 2,249,984 7/1941 Seever 72/404 2,534,613 12/1950 Meley 29/6 2,535,295 12/1950 Lafont 72/404 2,790,227 4/1957 Fine 29/6 Primary Examiner-Richard J. Herbst Assistant Examiner-M. J. Keenan Attorney, Agent, or Firm-Eric H. Waters [57] ABSTRACT Forging of shaped elements on or from bars is performed by the upsetting of a section of the bar along its axis with a simultaneous squeezing of a part of this section which takes place in a direction transverse to the axis of the bar. Shaping of the product takes place in a device which cooperates with a press or is driven in another way. The device consists of two sets. A set consists of a plate with bearing rollers, a housing for dies with bearing rollers for connectors located between these rollers and linking elements which suspend the housing of the dies to the plates. To the plates, shaping punches are fixed. During forging operation, the bar is fastened between split dies.

7 Claims, 30 Drawing Figures PATENIH] FEB 2 5 I975 SHEET 5 OF 5 Fig.4?

METHOD OF FORGING OF VARIOUS SHAPED ELEMENTS ON ELONGATED BARS AND A DEVICE FOR THE USE OF THIS METHOD FIELD OF INVENTION The invention relates to methods for the shaping of various shaped elements on or from elongated bars by means of forging and apparatus for the use of this method.

BACKGROUND In forging processes, plastic strain is caused by two or more tools performing a rectilinear-return movement or a swinging movement towards each other. This kind of plastic shaping of a body of metal takes place, according to known techniques, in two ways.

According to one known method, the shaping tools move in the direction of the longitudinal axis of the material involved. The effect of such plastic strain is upsetting of the material which means the shortening of the height or the length of the worked material. This relates to operations taking place on or in hammers, presses and horizontal forging machines. The other known method requires the shaping tools to move in a direction perpendicular to the axis of the material to be worked. Such movement of tools causes the lengthening or widening of the worked material. This type of shaping is achieved on or in hammers, presses or swaging machines.

In the case of products which are in the shape of rods having two shoulders of optional length, between which there is a section which is thinner than the section of the initial rod, the hitherto known methods do not enable producing a profiled part of a forging in one forging operation. Heretofore, such products have been made either entirely by machining or they are forged in several operations on or in forging machines such as horizontal forging machines, hammers, friction presses or mechanical presses.

In case of a rod having a brake cam with two shoulders on its end, it is necessary first to upset the end of the rod on a horizontal forging machine, and .then to perform die forging on a hammer or press. However, the production of a rod with a profiled part with a contraction in the middle of the rod requires a prior upsetting in the tool described in Polish Pat. No. 49818, and then it has to be die forged as in the case of a brake cam, because of the substantial length of the cylindrical part from both ends of the profiled center. Because of the substantial difference of the cross-sections when die forging, there occurs in both cases a big flashing in the central part of the profiled forging. It involves considerable costs due to the use of at least two machines, as well as material losses caused by the flashing and a decreased tool life. Similar difficulties appear in forging a bar with protrusions as will be hereafter shown.

SUMMARY OF THE INVENTION An object of the present invention is to remove the above faults and disadvantages.

This and other objects are achieved, in accordance with the invention in that a bar section with a length L is upset in the direction of the bar axis with a simultaneous squeezing perpendicularly to the axis of the rod whereby the squeezing may occur from the beginning of upsetting or can follow the initial upsetting and takes place in the upset part of the bar. Such shaping of the product is achieved with both split dies approaching each other or a buffer punch. This causes the upsetting of the part of the bar closed between the faces of the dies or between the faces of the dies and the buffer punch. During this operation, simultaneous shift in the direction perpendicular to the bar axis of two or more shaping punches takes place. These punches have cavities chosen according to the shape of the product and they squeeze a part of the rod which is within their reach. For application of this invention, a device is used which has symmetric connectors located symmetrically in relation to its axis. In the center of the device, two shaping punches are fixed to an upper and to a lower plate.

An advantage in theapplication of this invention is a substantial decrease of the cost connected with the useage of the machines involved, a decrease of material losses due to elimination of flashing and an increase of tool life. Furthermore the invention gives new technological possibilities enabling the shaping of some products which hitherto could not be made by plastic working.

BRIEF DESCRIPTION OF DRAWING The drawing shows an example of this new method of forging, as well as a device for the application of this method.

In the drawing:

FIGS. l(a)-l(c) illustrate three steps in the forging of a product;

FIGS. 1(a') and 1(2) are cross-sectional views along lines I(d)-I(d) and I(e) l(e) respectively;

FIGS. 2(a)2(d) illustrate several steps in the forging of different products;

FIGS. 2(e), 2(j) and 2(g) are cross-sectional views along lines II(e)-II(e), II())II(f) and II(g)II(g) respectively;

FIGS. 3(a) and 3(b) are respectively a side view and a cross-sectional view along line III(b)III(b) of a rod with a profiled part having a contraction in the middle of the rod;

FIGS. 4(a) and 4(b) are respectively a side view an a cross-sectional view along line IV(b)-IV(b) of a rod on the end of which there is a brake cam with two shoulders;

FIG. 5 schematically illustrates split dies and shaping v punches with a rod fixed, the arrows indicating the direction of the movement of the tools during a shaping operation;

FIG. 6 illustrates the positions of the tools in the final phase of shaping;

FIG. 7 is a cross-sectional view along line VII-VII in FIG. 6;

FIG. 8 illustrates a rod fastened in the split dies while the end of the rod rests on the face of a buffer punch;

FIG. 9 illustrates the position of the tools at the end of the shaping operation, where the shaping punches have a cavity for forging brake cams;

FIG. 10 is a cross-sectional view along line X-X in FIG. 9;

FIG. 11 is a sectional similar to that of FIG. 10, but with the application of tools of different shape and including shaping punches with a different die division than shown in FIG. 10;

FIGS. 12(a) and 12(b) are respectively a side view and a cross-sectional view along line XII(b)XII(b) of a bar with lateral protrusions;

FIG. 13 schematically illustrates split dies with a fastened bar and shaping punches before the shaping operation of the forging shown in FIGS. 12(0) and 12(b);

FIG. I4 illustrates the position of the tools at the end of the shaping operation;

FIG. 15 is a cross-sectional view along line XVXV in FIG. 14 illustrating the shape of the shaping punches;

FIG. 16 is a longitudinal section of a device for forging in accordance with the invention. the left side showing the position of the tool at starting and the right side showing the position of the tool at the meeting of the fixed dies with the rod being worked; and

FIG. 17 illustrates the same tool in the final phase of the shaping of the product.

DETAILED DESCRIPTION In FIG. 1(a) is shown a rod 20 having a portion with a length L1 and having a longitudinal axis 22 perpendicular to which is an orthagonal axis 24. The rod 20 has ends 26 and 28.

As appears in FIG. 1(b) opposing longitudinal forces may be applied to the rod 20 as indicated by arrows 30 and 32. These forces are applied along the longitudinal axis 22 so that the length L1 indicated hereinbelow is reduced to length L2, thus causing the rod or bar 20 to be upset".

If at the same time (i.e., simultaneously with the application of the opposed longitudinal forces) perpendicular forces are applied transversely of the rod 20 at the upset portion, a shape may be applied to the upset portion as appears in FIGS. 1(b) and 1(d). This means that there will be generated two protruding portions 34 and 36 and a central connecting portion 38 which will preferably have a transverse dimension which is less than that of the balance of the rod.

FIG. 1(c) illustrates that the portions 34 and 36 may be further shaped to form disc like elements or cams or whatever other specific shape is desired, such shape being applied to the upset portion as the upset portion is being formed. The cross-section of FIG. I(c) is in FIG. l(e).

FIGS. 2(a)-2(d) illustrate the formation of a different shape by the forging of a rod or bar 50. In FIG. 2(a) is indicated a portion having a length L] which is the portion of the rod 50 which is to be upset by opposed longitudinal forces applied along the longitudinal axis of the rod 50, there being a simultaneous squeezing of the portion being upset to give the rod a portion of increased diameter as indicated at 52 in FIG. 2(b), the cross-section of portion 52 appearing in FIG. 2(e).

FIGS. 2(a) and 2(d) shown in cross-section respectively in FIGS. 29) and 2(g) illustrate that the portion 52 may be given a further reduction in length as indicated by L3 and L4. The result is a key shape involving opposed keys 54 and 56 as appears in FIGS. 2(d) and (8)- FIGS. 3(u) and 3(d) show a rod 60 having a central portion 62 which is upset and shaped in the manner indicated hereinabove with the upset and shaped portion being positioned exactly in the center of the rod.

FIGS. 4(a) and 4(1)) show an upset portion wherein the shape is imparted as indicated at 70 at one end of the rod.

The shaping of the profiled part of a rod Rtakes place, as is seen in FIGS. 5 and 6, by simultaneous movement of dies 1 and l' in the direction of the center as shown by arrow A1 and by the same movement of the shaping punches 2 and 2'. The dies 1 and I by movement in the direction of arrows A2 cause the upsetting of part of the rod 3 between the faces of the dies while the shaping punches 2 and 2' cause squeezing of the upset part of the rod.

In FIG. 7, a cross-section is shown of the central part of the rod of FIG. 3 shaped by this method.

FIGS. 8 and 9 show the shaping of a similar profiled part on the end ofa rod RI. FIGS. 10 and 11 represent different forms of shaping punches P1 and P2. FIGS. 12(a) and 12(b) illustrate a rod 80 having lateral protrusions 82 and 84.

FIG. 13 schematically illustrates apparatus for obtaining the forging of a rod as indicated hereinabove with respect to FIGS. 12(0) and 12(b). FIG. 14 illustrates the bringing of the die elements 2 and 2 together and the sandwiching of the elements by the dies 1, I to form an upset portion in the manner discussed hereinabove. FIG. 15 is a cross-sectional view of FIG. 14 taken along line XVXV.

FIGS. 16 and 17 shown an example of a multiconnector device which, being fixed on a mechanical or hydraulic press or having its own drive, imparts to the dies 1 and 1, self fastening to the worked rod 3 as well as to the shaping punches 2 and 2', a movement in the direction of the center of the device causing plastic shaping of that part of the rod which is enclosed between the faces of the dies.

This device is composed of two similar sets, as upper one and a lower one. The upper set, fastened to a press ram, is composed of a plate to which bearing rollers 8 are fixed. Similar bearing rollers are fixed to the housing of the die 9. Between the rollers, there is a toggle connector 10. The rollers 8 are connected with each other by linking elements II (FIG. I7).

The lower set of the multiconnectcr device is fastened to the press table. The organization of the parts I is similar to the upper set. The device is provided with springs or corresponding pneumatic cylinders (not shown) and which urge the housing of the dies to their starting position as controlled by an end stop 12.

Both sets, the upper and the lower, are guided towards each other by means of sliding columns 13. The corresponding symmetrically inclined toggle connectors l0 and 10' cause, as a consequence of the press pressure, the self fastening of the worked rod 3 during the downward movement of the press ram at the moment the fastening dies 1 and 1' meet.

Then as a consequence of further movement of the press ram, the approaching of (lies 1 and 1' occurs which causes the upsetting of the rod. The simultaneous approaching to each other of the shaping punches 2 and 2' fastened to the upper plate 7 and to the lower plate 7 causes the expanding of the upset part of the rod.

It has to be noted that, due to the simultaneous movement of the dies 1 and 1' and of the punches 2 and 2, the effect of the perpendicular and horizontal plastic strain occurs simultaneously, giving in effect a composite shape to the product with one stroke of the press. After the press ram reaches the lower stroke point, the return movement of this ram occurs and the device returns to its starting point.

What is claimed is:

1. A method of forging a predetermined shape into an elongated rod comprising upsetting the rod by applying opposed longitudinal forces on the rod and squeezing the rod perpendicularly thereof at the thusly resulting upset portion of the rod concurrently with the upsetting of the rod to apply transverse forces sufficient to deform said upset portion of the rod, the transverse forces being applied from opposite sides of the rod so that the upset and deformed portion of the rod is coaxial with the remainder of the rod, said portions of the rod to which the longitudinal forces are applied being moved towards one another in the course of upsetting of the rod, while the transverse forces are simultaneously applied and moved towards one another to progressively deform the portion of the rod being upset during the course of said longitudinal movement of the portion of the rod during upsetting.

2. A method as claimed in claim 1 comprising squeezing the upset portion to said predetermined shape.

3. A method as claimed in claim 2 comprising clamping the ends of the rod by opposed perpendicular forces prior to upsetting the rod.

4. A method as claimed in claim 2 wherein the upset portion is squeezed and deformed to form two spaced portions spaced by a connecting portion which has at least one transverse dimension smaller than the remainder of said rod.

5. Apparatus for forging a shape into an elongated rod, said apparatus comprising first means for clamping the rod at the ends thereof and for applying opposed longitudinal forces to said rod towards the center of the latter to upset the rod, and second means for effecting simultaneously with the upsetting of the rod squeezing ofthe thusly upset portion with forces directed perpendicularly of said rod in opposite directions to apply transverse forces sufficient to deform the portion of the rod being upset, said first and second means collectively comprising upper and lower plates, die elements respectively associated with said plates, rollers on said plates and die elements, links between the rollers on the plates and on said elements, and toggle connectors between the rollers on the plates and on said elements, the die elements being positioned in pairs at the ends and center of the rod, in symmetrical disposition, and the links and toggles also being arranged in symmetrical disposition with respect to the upper and lower plates and die elements so as to apply said longitudinal forces and the perpendicular squeezing forces in concert through said die elements as the said plates are respectively moved together, said pair of die elements at the ends being movable longitudinally towards one another when the plates move together while simultaneously therewith the pair of die elements at the center of the rod are movable transversely in equal amounts towards the longitudinal axis of movement of said die elements at the ends.

6. Apparatus as claimed in claim 5 wherein said second means includes opposed elements including recesses facing towards the ends of the rod.

7. A method as claimed in claim 1 wherein the rod is squeezed symmetrically at the upset portion to provide a substantially symmetrical resulting shape with respect to the longitudinal axis along which the longitu- 

1. A method of forging a predetermined shape into an elongated rod comprising upsetting the rod by applying opposed longitudinal forces on the rod and squeezing the rod perpendicularly thereof at the thusly resulting upset portion of the rod concurrently with the upsetting of the rod to apply transverse forces sufficient to deform said upset portion of the rod, the transverse forces being applied from opposite sides of the rod so that the upset and deformed portion of the rod is coaxial with the remainder of the rod, said portions of the rod to which the longitudinal forces are applied being moved towards one another in the course of upsetting of the rod, while the transverse forces are simultaneously applied and moved towards one another to progressively deform the portion of the rod being upset during the course of said longitudinal movement of the portion of the rod during upsetting.
 2. A method as claimed in claim 1 comprising squeezing the upset portion to said predetermined shape.
 3. A method as claimed in claim 2 comprising clamping the ends of the rod by opposed perpendicular forces prior to upsetting the rod.
 4. A method as claimed in claim 2 wherein the upset portion is squeezed and dEformed to form two spaced portions spaced by a connecting portion which has at least one transverse dimension smaller than the remainder of said rod.
 5. Apparatus for forging a shape into an elongated rod, said apparatus comprising first means for clamping the rod at the ends thereof and for applying opposed longitudinal forces to said rod towards the center of the latter to upset the rod, and second means for effecting simultaneously with the upsetting of the rod squeezing of the thusly upset portion with forces directed perpendicularly of said rod in opposite directions to apply transverse forces sufficient to deform the portion of the rod being upset, said first and second means collectively comprising upper and lower plates, die elements respectively associated with said plates, rollers on said plates and die elements, links between the rollers on the plates and on said elements, and toggle connectors between the rollers on the plates and on said elements, the die elements being positioned in pairs at the ends and center of the rod, in symmetrical disposition, and the links and toggles also being arranged in symmetrical disposition with respect to the upper and lower plates and die elements so as to apply said longitudinal forces and the perpendicular squeezing forces in concert through said die elements as the said plates are respectively moved together, said pair of die elements at the ends being movable longitudinally towards one another when the plates move together while simultaneously therewith the pair of die elements at the center of the rod are movable transversely in equal amounts towards the longitudinal axis of movement of said die elements at the ends.
 6. Apparatus as claimed in claim 5 wherein said second means includes opposed elements including recesses facing towards the ends of the rod.
 7. A method as claimed in claim 1 wherein the rod is squeezed symmetrically at the upset portion to provide a substantially symmetrical resulting shape with respect to the longitudinal axis along which the longitudinal forces are applied. 